Merchandiser system and method for controlling the drying of previously baked goods

ABSTRACT

A merchandiser system and method for thawing, displaying, and warming previously baked dough products, such as cookies, under controlled drying conditions, including a warming compartment and a merchandiser. The merchandiser controls the drying of moisture in the thawed, baked products to maintain the organoleptic and/or texture properties of the products at essentially the same level as those of freshly baked products for a period of at least about 2 hours.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application is a continuation of U.S. patentapplication Ser. No. 09/872,098, filed on Jun. 1, 2001, U.S. Pat. No.6,455,816, the content of which is hereby expressly incorporated hereinby reference thereto.

TECHNICAL FIELD

[0002] The present invention is directed to a method and apparatus forwarming and controlling the drying of previously baked dough products toretain their originally baked characteristics over time. In particular,the apparatus and method control the moisture in the previously, frozen,baked good, such as a cookie or other baked dough product, to provide adesired drying profile over an increased period of time in order tomaintain its originally baked dual texture.

BACKGROUND OF THE INVENTION

[0003] In order for previously baked products to maintain a high qualityduring display for sale, they have to be handled under preciseconditions during their storage. They are usually heated throughout thevast majority of their display period to provide a warmed baked productready for sale and consumption. This has significant consequences fortextural characteristics, including bite and mouthfeel.

[0004] Previously baked dough products are displayed for sale in manydifferent ways. Many such products are sold in sealed boxes or bags toretain the moisture content. Such sealed containers, however, result inthe equilibration of moisture in the baked products over a period oftime. Any moisture gradient that exists after baking is eliminated overtime as the moisture migrates from the portion(s) having more moistureto the portions having less. This tends to result in a baked productthat is soggy or, at best, uniformly moist and soft, such that it willnot have a fresh baked character, i.e., crisp and chewy, after storagefor a period of time.

[0005] Other previously baked products are sold in a large glass displaycase that is often open to the air on at least one side. Such displaystypically result in significant or even complete loss of moisture fromthe previously baked product over time, as the moisture evaporates intothe air. The products become hard due to the drying out of the moisture.This is particularly true of heated displays, and such heating can occursimply from long-term exposure to incandescent illumination used in manysuch displays to make the baked products more attractive to theconsumer.

[0006] Existing devices to simultaneously heat and display bakedproducts using conduction and convection are available for pizzas andoperate at temperatures high enough to keep cheese in a soft and atleast partially molten form, i.e., from 145° F. to 160° F. Also, many ofthese conventional heated devices for warming baked products typicallydispose these products on a wire rack or a round pizza pan that exactlyfits the product. At least some such prior art devices have athermometer placed near the heat source and use a heat source at the topof the enclosure to directly heat at least the top pizza. Several suchdevices of this type are sold by Wisco Industries, Inc.

[0007] U.S. Pat. No. 5,132,520 discloses an apparatus used to toastbread and buns, which then hot-holds the toasted bread and buns.

[0008] U.S. Pat. Nos. 6,098,529 and 6,159,514 disclose a heatedmerchandiser for displaying prepared donuts using both hot and coldlight sources. The reference discloses that some heating occurs totemperatures of 85° F. to 110° F.

[0009] In sum, there is no existing apparatus or method to facilitatethe display of a previously baked product that can maintain its freshbaked profile over a period of time to entice the consumer to purchaseand consume the product. Despite the difficulties of retaining the freshbaked profile of previously baked products over time, retailers andtheir customers desire such products. For added convenience, economicreality, and for culinary delight, it is therefore desirable to haveavailable previously baked products that retain their fresh bakedcharacter over time without deterioration of desired organolepticproperties.

[0010] Thus, there remains a need for equipment and methods to providesuch a stable baked product that retains the character of a fresh bakedproduct. The present invention teaches such equipment and methodswithout the aforementioned disadvantages of existing equipment andmethods.

SUMMARY OF THE INVENTION

[0011] The invention relates to a merchandiser for displaying andwarming previously baked dough products under controlled dryingconditions. This merchandiser includes an enclosure having one or morewall members that define an interior space, with at least a portion ofone of the wall members being transparent, an aperture for access intothe interior space, at least one support surface for supporting one ormore previously baked dough products that contain a predeterminedaverage moisture level therein, at least one mounting structureassociated with the enclosure for mounting and positioning each supportsurface at a user accessible location in the interior space of theenclosure, and a heat source for providing heated air in the enclosure.The support surface contacts at least a portion of the previously bakedproducts so that those portions are shielded from direct contact withthe heated air such that the drying of moisture in the baked products iscontrolled to maintain the organoleptic and/or texture properties of theproducts at essentially the same level as those of freshly bakedproducts for a period of at least about 2 hours.

[0012] Advantageously, the baked products have a relatively flat baseportion and a top portion, and wherein each support surface includes atray member having a flat upper surface that supports and contacts thebase portions of the baked products so that those base portions areshielded from heated air in the enclosure and dry at a rate that isdifferent from that of the top portions of the baked products.

[0013] For convenience in placing the tray members into the enclosure,the tray members include a lip extension on at least one side thereof.This lip also assists in preventing baked products from sliding off thetray member. Thus, the tray member may be removably mounted upon themounting structure to facilitate product placement thereon and cleaningthereof.

[0014] The enclosure preferably includes front and rear walls, and theheat source comprises electrical illumination which generates light toilluminate the baked products as well as heat to warm the air in theenclosure. The electrical illumination may be light bulbs that arearranged symmetrically within the enclosure to direct light and heatedair substantially uniformly toward the tray member and the bakedproducts thereon. These light bulbs generally have a total wattage ofabout 75 W to 130 W and are placed about 14 cm from the tray member.

[0015] If desired, the heat source may be a heating element for heatingthe air in the enclosure. Although direct conduction heating of theproducts can be at least in part accomplished by disposing a heat sourcein the tray, it is preferred that the heating element be locatedsufficiently away from the baked products and tray such that directheating of the products on the tray by the element is substantiallyavoided. Such direct heating can overcook and dry out the bakedproducts. Also, the heat source should operate to maintain the interiorspace of the enclosure at a set temperature of about 95° F. to about150° F. so that the baked product retains its organoleptic and/ortexture properties for a period of at least about 6 hours. In preferredembodiments, the temperature is within about 10° F., or within about 5°F. of the desired set temperature throughout the entire enclosure.

[0016] For better heat control in the enclosure, the merchandiserfurther includes a temperature control system capable of maintaining theheated air to within about 5° F. of a desired temperature at a givenpoint over time. Preferably, the temperature is maintained at a constantto within about 2° F. of the desired temperature at a given point overtime. This can be achieved by use of a proportional controller thatprovides an error signal that is proportional to the differential ofactual temperature from the set point. Generally, the proportionaltemperature control system comprises a solid-state rectifier controlledby a proportional circuit and a thermistor sensor to provide the exactamount of electric power needed to maintain a constant temperature.Also, at least one thermometer can be placed sufficiently far from eachaperture of the enclosure and each heat source to accurately monitor thetemperature in the enclosure.

[0017] The invention also relates to a cookie merchandiser fordisplaying and warming previously baked cookies under controlled dryingconditions. This device includes an enclosure having an interior space,at least one aperture such as a door for access into the interior space,at least one support surface for supporting one or more previously bakedcookies that contain a predetermined average moisture level of about 5to 9 percent by weight therein, a structure associated with theenclosure for mounting and positioning each support surface at a useraccessible location in the interior space of the enclosure, and a heatsource for providing heated air in the enclosure wherein the supportsurface contacts at least a portion of the cookies so that thoseportions are shielded from direct contact with the heated air such thatthe drying of moisture in the cookies is controlled to maintain theorganoleptic and/or texture properties of the warmed cookies atessentially the same level as those of fresh baked cookies for a periodof at least about 2 hours.

[0018] Preferably, the enclosure includes a roof structure for receivingand concealing the heat source and the vertical walls include a frontwall, pair of side walls, and a rear wall disposed between the front andside walls, wherein more than one wall is made at least partiallytransparent to facilitate viewing of the baked products therein fromdifferent angles. Also, the roof structure is adapted on at least oneouter surface to receive advertising concerning the cookies therein,which advertising is visible to the user.

[0019] Another aspect of the invention relates to a method fordisplaying and warming previously baked dough products under controlleddrying conditions. This method includes the steps of providingpreviously baked dough products that contain a predetermined averagemoisture level in an enclosed space upon a support surface such that thesupport surface contacts at least a portion of the baked products, andproviding heated air in the enclosed space so that those supportedportions of the baked products are shielded from direct contact with theheated air to control the drying of moisture from the baked products andto maintain their organoleptic and/or texture properties at essentiallythe same level as those of freshly baked products for a period of atleast about 2 hours. The heated air can be circulated in the enclosedspace to assist in the controlled drying of the baked products.Advantageously, the interior space is maintained at a temperature ofabout 95° F. to 150° F. so that the baked products retain theirorganoleptic and/or texture properties for a period of at least about 6hours.

[0020] Alternatively, the method includes the steps of providingpreviously baked cookies that contain a predetermined average moisturelevel in an enclosed space upon a support surface such that the supportsurface contacts at least a portion of the cookies, and providing heatedair in the enclosed space so that those supported portions of thecookies are shielded from direct contact with the heated air in order tocontrol the drying of moisture from the cookies and to maintain theirorganoleptic properties at essentially the same level as those offreshly baked cookies for a period of at least about 2 hours.

[0021] Another aspect of the invention relates to a method for providinga moisture gradient in a plurality of previously baked products. Thismethod comprises disposing the previously baked products in an enclosureon a support member therein that contacts at least a portion of the baseof each product to inhibit moisture loss from the products, andcirculating a heated gas within the enclosure to provide the moisturegradient in the plurality of baked products over a period of at leastabout 2 hours. Again, the heated gas preferably is heated air.

[0022] At least about 34 percent of the base of each product contactsthe support member and the enclosure is configured and arranged toreduce the loss of moisture therefrom in order to achieve this moisturegradient. The gas may be heated to a predetermined temperature to warmthe previously baked product and preferably at least about 50 percent ofthe base of each product contacts the support member. In preferredembodiments, at least about 75 percent or at least about 100 percent ofthe base of each product contacts a support member.

[0023] In this invention, the baked products to be warmed have a centralportion and an outer portion arranged about the central portion so as toretain a moisture gradient that comprises at least about 8 percent watercontent in the central portion of the baked product and below about 7percent water content in the outer portion of the baked product forseveral hours during warming. The central portion typically representsthe innermost 33 to 66% of the area or volume of the product while theouter portion represents the outermost 17 to 33% of the area or volumeof the product. Preferably, the moisture gradient comprises at leastabout 7.5 percent water content in the central portion and below about 4percent water content in the outer portion after about 6 hours in theenclosure. When the baked product is a substantially round cookie ofabout 2 to 5 inches in diameter, the central portion is a width of about¾ inch to 1¼ inch and the outer portion is a band having a diameter ofabout ¾ to ¼ inch as measured from the periphery of the cookie.

[0024] The invention also relates to a baked cookie having a dualtexture, i.e., crisp and chewy, and an average moisture level of about6.5 to 10 weight percent water moisture after baking, which cookie has adual texture and retains the average moisture level for at least about 2to 8 hours after baking. The dual texture of these cookies comprises acentral zone having a diameter of at least about ¾ inch at the center ofthe cookie and an outer zone of a band having a width of at least about¼ inch adjacent the edge of the cookie and disposed about the centralzone, and wherein the outer zone has a lower moisture content than thecentral zone.

[0025] The invention relates to a modular merchandiser system fordisplaying and warming previously baked dough products under controlleddrying conditions. This device comprises a merchandiser section and awarming section.

[0026] The merchandiser is generally an enclosure having one or morewall members that define an interior space, with at least a portion ofone of the wall members being transparent, at least one aperture foraccess into the interior space, at least one support surface forsupporting one or more previously baked dough products that contain apredetermined average moisture level therein, and at least one mountingstructure associated with the enclosure for mounting and positioningeach support surface at a user accessible location in the interior spaceof the enclosure, and a heat source for providing heated air in theenclosure. Thus, the support surface contacts at least a portion of thepreviously baked products so that those portions are shielded fromdirect contact with the heated air such that the drying of moisture inthe baked products is controlled to maintain the organoleptic propertiesof the products at essentially the same level as those of freshly bakedproducts for a period of at least about 2 hours.

[0027] The warming section comprises a warming compartment disposedadjacent to the merchandiser. Preferably, the merchandiser is disposedover the warming compartment. The warming compartment advantageouslycomprises a heat source that operates at a temperature of about 300° F.to 475° F. to thaw and begin to warm previously baked frozen cookies inless than about 10 minutes. Preferably, the warming compartmentcomprises a heat source that operates at a temperature of about 350° F.to 425° F. to thaw frozen cookies previously baked in less than about 5minutes. The warming compartment is sized and configured to receive atleast one support surface that is also used in the merchandiser forwarming and displaying the warmed, baked products, and includes at leastone mounting member for engaging the at least one support surface.

[0028] The warming compartment may also include at least one controllerfor automatic cycling to alert an operator that the thawing cycle iscompleted. Furthermore, this controller may open the warming compartmentwhen the heating cycle is complete, such as by ejecting the supportsurface of thawed, baked goods after the compartment opens. For securityand safety, the controller can initiate an audible or visible alarm whenthe heating cycle is completed.

[0029] Another aspect of the invention relates to a method fordisplaying and warming previously baked, frozen, dough products undercontrolled drying conditions. This method includes the steps of thawingthe frozen dough products on a support surface which contacts at least aportion of the base of each frozen dough product, the thawing beingconducted at a temperature of about 300° F. to 475° F. for less thanabout 10 minutes to warm the frozen dough products while retaining adesired moisture profile therein, and displaying the warmed doughproducts in an enclosed space upon the support surface while providingheated air in the enclosed space so that those supported portions of thebaked products are shielded from direct contact with the heated air tocontrol the drying of moisture from the baked products and to maintaintheir organoleptic properties at essentially the same level as those offreshly baked products for a period of at least about 2 hours.

[0030] Advantageously, the interior space is maintained at a temperatureof about 95° F. to 150° F. so that the baked products retain theirorganoleptic and/or texture properties for a period of at least about 6hours. If desired, the heated air can be circulated in the enclosedspace to assist in the controlled drying of the baked products and toreduce the warming-up time of any frozen baked products. If so, theheated air is circulated within the enclosed space to provide themoisture gradient in the plurality of baked products over a period of upto about 6 hours.

[0031] At least about 34 percent, preferably at least about 50% of thebase of each product contacts the support member and the enclosure isconfigured and arranged to reduce the loss of moisture therefrom inorder to achieve this moisture gradient. The gas may be heated to apredetermined temperature to warm the previously baked product andpreferably at least about 50 percent of the base of each productcontacts the support member. In preferred embodiments, at least about 75percent or, ideally, at least about 100 percent of the base of eachproduct contacts the support member.

[0032] In this invention, the baked products to be warmed have a centralportion and an outer portion arranged about the central portion so as tomaintain a moisture gradient that comprises at least about 8 percentwater content in the central portion of the baked product and belowabout 7 percent water content in the outer portion of the baked product.The central portion typically represents the innermost 33 to 66% of thearea or volume of the product while the outer portion represents theoutermost 17 to 33% of the area or volume of the product. Preferably,the moisture gradient comprises at least about 7.5 percent water contentin the central portion and below about 4 percent water content in theouter portion after about 6 hours in the enclosure. When the bakedproduct is a substantially round cookie of about 3 to 5 inches indiameter, the central portion is a width of about ¾ inch to 1¼ inch andthe outer portion is a band having a diameter of about ¼ to ¾ inch.

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Further features and advantages of the invention can beascertained from the following detailed description that is provided inconnection with the drawing(s) described below:

[0034]FIG. 1 illustrates a convection-type merchandiser according to theinvention;

[0035]FIG. 2 illustrates a conduction-type merchandiser according to theinvention;

[0036]FIG. 2A illustrates a cutaway of a support surface that can beused in the conduction-type merchandiser; and

[0037]FIG. 3 illustrates a modular merchandiser system having amerchandiser and a warming compartment according to the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0038] The present invention advantageously provides a device and methodfor displaying and warming previously baked dough products, such ascookies, brownies, muffins, and the like, under controlled dryingconditions. Preferably, the device is used to display and warm bakedsweet dough products. The invention permits and facilitates food servicesales, which are baked products prepared at a centralized foodpreparation center, if desired, and distributed later to the retailersthat intend to display and sell the product according to the invention.The device includes an enclosure to display the baked products whilethey are maintained in a substantially fresh baked state, i.e., bycontrolling the drying of the products. In particular, this controlleddrying is achieved by creating a moisture gradient in the baked product.For cookies, controlled drying avoids moisture equilibration in thebaked product and allows the cookie to retain a crisper, drier, outerzone and a chewier, moister central zone, i.e., a dual texture. Thisalso avoids the need to use two or more dough formulations to achievetexture variation in the baked products. The device typically includes aheat source to heat the baked products to provide the controlled dryingthereof. In one embodiment, the invention warms and displays thepreviously baked dough products without the need for an oven.

[0039] The enclosure typically has one or more wall members that definean interior space, with at least a portion of one of the wall membersbeing transparent, at least one aperture for access into the interiorspace, at least one support surface for supporting one or morepreviously baked dough products that contain a predetermined averagemoisture level therein, and at least one mounting structure associatedwith the enclosure for mounting and positioning each support surface ata user accessible location in the interior space of the enclosure. Thewall members can be formed of any suitable material. At least one wallis preferably transparent to lure the customer to view the deliciousbaked treats therein without having to open the enclosure, whichminimizes the amount of times the enclosure is accessed. Opening thechamber too often can permit moisture to escape the chamber andaccelerate drying. One or more small air gaps, however, can be includedin the enclosure.

[0040] In a preferred embodiment, at least three or four wall membersare transparent or are at least sufficiently transparent to permit aviewer to see the baked products therein. In another preferredembodiment, a small air gap is present in between at least one of theapertures and a wall member to permit aroma from the warmed, bakedproducts to escape into the surrounding atmosphere. The air gap can alsobe, for example, one or more holes in one or more wall members. This airgap advantageously permits consumers to smell the baked products withouthaving to open the aperture, although additional aroma does escape theenclosure each time the aperture is opened. The air gap should be sizedsufficiently to permit a small amount of aroma to escape but smallenough to retain substantially all of the moisture within the enclosure.

[0041] The aperture to access the baked products is typically a door,either hinged or sliding, to permit rapid and easy access to theproducts when a purchase is desired. Other types of suitable apertureswill be readily apparent to those of ordinary skill in the art. Onepreferred aperture is to have a door on the same side of the enclosureas a transparent wall member so that a consumer can see the bakedproduct and open the aperture to grab the desired baked product. Anotherpreferred embodiment is to have a second aperture on the opposite wallmember or an adjacent wall member for the retailer to add additionalbaked products. As the merchandiser is emptied of baked products byconsumers, product replacement can be made a few at a time, or an entiretray can be removed and a fresh tray of baked products loaded therein.The opposite wall member is a preferred location for the second door,although placement of the merchandiser in a corner location of a roomwould require placement of the second aperture on an adjacent wallmember for simplicity of access.

[0042] The at least one support surface typically includes a surfacethat is at least substantially planar. The surface(s) can be, forexample, a tray or sheet on which to display the baked products in theenclosure. The surface(s) is shaped and dimensioned to fit in theenclosure, which will for instance have a square or rectangular shape.The surface(s) each have at least one edge that can also optionally beturned upward or downward to form a lip or notch. An upward lip can beincluded to inhibit or prevent the baked goods from sliding or fallingoff the surface. A downward lip or notch can be included on the surfaceto help position the surface within the enclosure such as by operativelyassociating the properly positioned surface against a lip or wiremounting assembly within the enclosure. Multiple lips or notches ineither or both directions can also be used to similar effect. Thesupport surface can also have notched corners where no lip exists. Thisembodiment avoids any point where more than two edges join, whichfacilitates cleaning the support surface between uses in themerchandiser.

[0043] In one preferred embodiment, the enclosure includes two surfaceson which to display a variety of baked goods. For example, cookies canbe disposed on one surface and brownies on the other. In a preferredembodiment, the surfaces are disposed in a vertically stacked fashionwith sufficient spacing therebetween to permit the consumer to both viewand access the baked products disposed thereon. The support surface canbe a tray used to bake the product in another apparatus, which tray canthen be moved into the merchandiser of the present invention withouthaving to individually place the baked products into the merchandiser.Alternatively, the support surface can be a sheet or wire rack uponwhich the previously baked products can be individually disposed beforethe sheet or rack is placed in the enclosure. These embodiments can helpavoid the need to keep the enclosure open to the ambient atmosphere fora long time, which affects the controlled drying of products remainingin the enclosure such as on a second support surface therein. It is alsodesired that the support surfaces, or trays, be sloped at an angle tomake more of the baked products more clearly visible to the consumer,which sloping also improves the convective heat transfer.

[0044] The previously baked dough products preferably have apredetermined average moisture level therein. The initial moisturecontent can be adjusted to take into account the subsequent loss ofmoisture that necessarily occurs depending on the residence time in themerchandiser while the warmed product still exhibits the desiredorganoleptic and/or texture properties. In one embodiment where theproduct is a cookie, the cookie contains an average of about 6 to 10weight percent moisture, preferably 5 to 8 weight percent moisture,after the initial baking and during storage thereof. The initialmoisture level can be controlled by the water in the recipe and duringthe baking of the product. These initial moisture levels are preferablyaccomplished by freezing the cookie as noted herein. Refrigeration orfreezing does not typically significantly alter the initial moisturecontent if the baked products are properly packaged. Preferably, theedge of the previously baked cookie has a moisture content of about 5 to6.5 weight percent after a one-hour residence time in the merchandiser.The center zone of the previously baked cookie has an initial moisturecontent of about 7 to 10 weight percent before warming, while in onepreferred embodiment the center zone has about 8 to 9 weight percentmoisture before warming. The initial moisture content represents thelevel of moisture present in the products immediately after baking, andthe invention preferably uses baked products that are packaged withinabout 1 hour of being baked, preferably within about ½ hour, to helpinhibit moisture loss in the product prior to packaging and subsequentwarming for display and sale.

[0045] The previously baked products are also preferably chilledpromptly after packaging, and preferably are frozen until ready for use.The freezing of previously baked products also facilitates retainingmoisture and a moisture profile within the products. Thus, the productsin which dual texture is desired are typically frozen in less than about4 days, preferably less than about 1 day, and more preferably less thanabout 6-8 hours, after baking. Such rapid freezing inhibits moistureequilibration, which reduces crispness of the edges of the bakedproducts. The freezing should also occur over a sufficient time topermit a reduction in condensation and inhibit or avoid possible frostformation inside the package of previously baked products. Thus, thecooling and freezing should take at least about 30 minutes. The specificrecipe of the baked product is not critical, however, using certaintypes of fats and humectant sugars, as well as varying the size andshape of the baked products, can modify the desired moisture profile inthe baked product when warmed for display and sale as is understood bythose of ordinary skill in the art, particularly with reference to thisdescription. For example, sugars that bind the moisture and inhibitmigration are desired to facilitate the dual texture products, althoughthe recipe is less important for baked products that are frozen soonafter baking as noted above. One particularly suitable baked productformulation is the cookie recipe available on the commercially availableTollhouse® chocolate chip morsel packaging, as well as reasonablevariations thereof.

[0046] The at least one surface in the enclosure is operativelyassociated with at least one mounting structure, which is itselfassociated with the enclosure. The mounting structure(s) are disposedfor mounting and positioning each support surface at a user accessiblelocation in the interior space of the enclosure. For example, themounting structure itself can be a wire rack, optionally fixed to thewalls of the enclosure, for receiving and supporting a support surfaceand the baked products typically disposed thereon. In a preferredembodiment, the mounting structure includes at least a lip or edge fixedto at least two opposing walls of the enclosure to guide and receive asupport surface so that no wire rack is needed in the central portion ofthe merchandiser. The use of a mere lip without a wire rack is desiredbecause an inattentive store clerk might be likely to ignore the supportsurface and dispose the baked products on the open wire rack, whichwould too rapidly dry out the baked products. The use of a lip as themounting structure forces the user to dispose the cookies on the supportsurface and install the surface in the enclosure.

[0047] The merchandiser also contains a heat source for providing heatedair in the enclosure. The heat source can be any suitable heat sourceavailable to those of ordinary skill in the art, such as incandescentlamps, conventional heat lamps, heating coils, and the like, as well ascombinations thereof. Incandescent lamps and heating coils are preferredsince they can be better adjusted to avoid heating the baked productstoo much or too fast. The heat source can be placed in a cage at the topof the enclosure, where the cage can help prevent injury to a consumerif the heat source fails catastrophically. Preferably, anincandescent-type heat source at the top of the enclosure includesPTFE-coated bulbs (TEFLON®) to inhibit such catastrophic failures,directional lamp bulbs to direct heat into a preferably more symmetricalheating pattern, or a combination thereof. The position, number, andwattage of the bulbs needs to be designed according to the size of theenclosure, as can be readily determined by those of ordinary skill inthe art based on the description herein. Preferably, at least twoincandescent bulbs are included in the heat source. In one preferredembodiment, each bulb is about 75 W to 140 W, preferably about 100 W to130 W, and located about 14 cm from the support surface such as a traymember

[0048]FIG. 1 shows a merchandiser according to the invention usingconvection-type heating. In FIG. 1, the heat source 5 is preferablydisposed in a housing 10 above the walls 12, 14, 16 of the enclosure 18.The housing 10 is preferably at least substantially sealed to the walls12, 14, 16 to inhibit moisture migration between the enclosure 18 andthe ambient atmosphere. The housing 10 is preferably opaque so that theconsumer will focus on the baked products 20, 22, 24, 26, etc., ratherthan the workings of the merchandiser. Another benefit of having ahousing 10 disposed over the enclosure 18 is that the housing 10 can bedesigned to receive advertising (not shown) regarding the baked products20, 22, 24, 26 in the associated enclosure 18. One or more fans, pumps,or other methods of moving air within the enclosure is optionally, butpreferably, used to help control drying and to facilitate asubstantially uniform temperature within the enclosure. Such air-movingdevice(s) (not shown) are preferably disposed in or adjacent to thehousing 10. Preferably, there are at least two outlets 30, 35 for everyinlet 40, which helps disperse the warmed air evenly into the enclosure18 as it exits the outlets 30, 35. In another preferred embodiment,there is one inlet 40 for returning air to be heated and two outlets 30,35 for warmed air to enter the enclosure 18 to warm the previously bakedproducts 20, 22, 24, 26. In one embodiment, the heat source 5 includesheat-producing lamps disposed in a direct line (not shown) above thesupport surface 45, 50 and in a symmetrical pattern so as to providesubstantially even heating via radiation to the baked products on thesupport surface. In a preferred embodiment, the heat source 5 includesheat-producing lamps disposed out of a direct line with the supportsurface 45, 50 so as to avoid application of radiation to heat the bakedproducts 20, 22, 24, 26. In this embodiment, the air-moving device(s) is(are) required to ensure convective heating of the baked products, whichwill facilitate substantially even heating thereof. It should beunderstood that convection heating for at least substantially all, orall, of the heating is desired to avoid overdrying the baked products inthe apparatus. Without being bound by theory, it is believed thatconvection forms a thin hardened moisture barrier on the skin of thebaked product to a greater extent than other forms of warming. This skinis believed to inhibit moisture migration from the central zone of thebaked product.

[0049] In two additional embodiments, the heat source includes heatingcoils disposed above or under the baked products. In either embodiment,the coils are preferably uniformly disposed to provide a symmetrical,and therefore even, heat pattern to the baked products. Preferably, asshown in FIG. 2, the coil(s) are disposed under the baked products 20,22, 24, 26 inside the mounting structure(s) or support surface(s) 45,50. FIG. 2A, a cutaway of the support surface 45 in FIG. 2, shows thecoils 60, 62, 64, 66, 68. In this design, there is preferably an air gapbetween the top of these heating coil(s) and the surface on which thebaked products are disposed. The air gap can be about 0.5 inch to 1 inchbetween the heating elements 60, 62, 64, 66, 68 and the baked productson the support surface. In another but less preferred embodiment, ringsor other flexible heating devices can be embedded within the supportsurface itself. This permits the shape of the heating device to matchthe shape of the baked product, e.g., round or rectangular, to heat justthe baked product without excess heating. While the trays are designedto support the bottom surfaces of the baked products, stacking mayincorrectly position the products on the trays. When the trays aredesigned with only partial heated areas, some products may not beproperly heated and warmed. Thus, convection heating is preferred inthese instances.

[0050] The convection heating of the baked products in the enclosure ofthe merchandiser preferably has the following parameters. The ReynoldsNo. of airflow in the enclosure is preferably below about 2300 to avoidsignificant turbulent mass transfer leading to unacceptable moistureloss. Preferably, the Reynolds No. is from about 1150 to 2300. For bakedproducts about 10 cm across (i.e., 4 inches), the preferred air velocityin the enclosure is about 0.1 m/s to 1 m/s to facilitate convectionheating while controlling drying. In a more preferred embodiment, theair velocity in the enclosure is about 0.2 m/s to 0.5 m/s (about 40 fpmto 100 fpm). Thus, if heat convection does not generate such airvelocity, one or more fans, pumps, or other well known devices can beincluded in the device to ensure suitable air velocity. Regardless ofthe type of heat source, it is preferable to exclude a temperature dialor controllable temperature setting on the merchandiser. The heattemperature settings are preferably factory-set so that clerks or otherretail personnel will be unable to turn the heat too high, which woulddry out the baked products too rapidly.

[0051] One of the support surfaces contacts at least a portion of eachpreviously baked product to shield those portions from direct contactwith the heated air, such that the drying of moisture in the bakedproducts is controlled to maintain the organoleptic properties of theproducts at essentially the same level as those of freshly bakedproducts for a period of at least about 2 hours. In one preferredembodiment, the properties are maintained for at least about 4 hours,and in another preferred embodiment, the properties are at leastsubstantially maintained for at least about 6 hours. The support surfacepreferably covers at least about 34 percent of the underside of eachbaked product. In one preferred embodiment, the surface covers at leastabout 50 percent, more preferably at least about 75 percent of theunderside of each baked product, and in another preferred embodiment,the surface covers at least about 95 percent of the underside of eachbaked product. In the most preferred embodiment, the entire bottomsurface of each baked product is contacted by a support surface tominimize moisture migration from the central zone of the baked productto be warmed. For example, it has been found that holes or gaps of lessthan about 3 mm in diameter (less than about 7 mm²) in the supportsurface are sufficiently small to avoid significantly contributing tothe over drying of cookies that have a diameter of 10 cm.

[0052] The merchandiser typically controls the drying of the bakedproduct so as to retain a sufficient moisture profile that is desirableto consumers. For certain products, an outer portion of the product hasa lower moisture content while a central or inner portion has a highermoisture content. Generally, the inner portion would represent theinnermost 33 to 66% of the area or volume of the product, and preferablythe innermost 40 to 50%. The outer portion represents the outermost 17to 33% of the area or volume of the product, and preferably theoutermost 20 to 25%. In a preferred embodiment, for a round-type bakedproduct having an overall diameter of about 5 to 12.5 cm (2 to 5inches), the central zone of the baked product can be understood to havea width of about 2 to 3 cm (about ¾ to 1¼ inch) while the outer zone canbe understood to have a diameter of about 0.6 to 1.6 cm (¼ to ¾ inch)measured from the perimeter of the round cookie.

[0053] For a baked cookie of this type, a desired moisture profile overtime can refer to a moisture loss of about 15 percent to 70 percent,preferably about 30 percent to 60 percent, of the moisture from theouter zone of the baked product over at least about 6 hours. For thecentral zone of this embodiment, the moisture loss is less than about 20percent, preferably less than about 15 percent, and more preferably lessthan about 10 percent, over at least about 6 hours. This controlleddrying provides an outer zone of a baked product that becomes somewhatdrier and crispier, while retaining a relatively moister, chewiercentral zone that provides desired organoleptic and/or texturecharacteristics to the consumer.

[0054] In a preferred embodiment when the baked product includeschocolate or peanut butter chips or similar inclusions, such as incookies or brownies, the baked product retains sufficient “chocolatepull” to provide a desired appearance and texture to the consumer.Chocolate pull is well understood by those of ordinary skill in the artto refer to the capacity of certain types of chocolate to besufficiently viscous to create a bridge of chocolate when a bakedproduct is pulled apart at the point where a chocolate chip is locatedbut not so viscous as to resist pulling. Chips that are too heatedbecome molten and chips not heated enough are too solid to pull apart.Those chips that exhibit chocolate pull are being maintained atessentially the correct temperature.

[0055] Another manner of measuring the desired moisture profile is withrespect to the firmness of the baked product as time progresses. Thecrisp/soft boundary when warming a rounded, previously baked productmoves inward over time at a controlled rate as moisture migrates out ofthe baked product in an apparatus of the invention. On the contrary, thecrisp/soft boundary is typically at the edge of the rounded product whenthe product is merely placed under ambient conditions, since themoisture equilibrates over the entire baked product. Conventionalwarming devices will move the crisp/soft boundary far too quickly to thecentral portion of the baked product, resulting in an undesirableproduct. The firmness of baked products, which helps determine thecrisp/soft boundary, can be measured using texture analyzer model TA-XT2commercially available from Stable Micro Systems of Godalming, Surrey,England. The device typically can be used with four to six prongs todetermine firmness, or stress, in a baked product warmed in an apparatusof the invention. The stress on previously baked cookies warmed in anapparatus of the invention can be as follows: for the outer zone, thestress is typically at least about 50 g/mm² after one hour of warmingand at least about 150 g/mm², preferably at least about 200 g/mm² after6 hours of warming; the central zone has a stress of less than about 25g/mm² after one hour and less than about 45 g/mm² after 6 hours ofwarming. Preferably, the stress is about 3 to 5 times greater at theouter zone compared to the center zone after one hour of warming andabout 5 to 7 times greater after six hours of warming.

[0056] In one embodiment, the merchandiser can be used to warm differenttypes of baked products, such as cookies and at least one of brownies,muffins, croissants, danish, and the like. It is typically desired forthe cookies to have a different moisture profile than the other types ofbaked goods. Thus, cookies or other products in which a dual texture isdesired can be placed on one support surface, i.e., a first shelf, andthe other product(s) can be placed on a second support surface, i.e., asecond shelf. When a more uniform moisture profile instead of one with asharper gradient is desired, such as for the brownies, a cover can beplaced over the baked products to avoid contact with the heated airflowing throughout the chamber (either from a fan or as a result ofconvection currents that will naturally arise due to heating). The coveris preferably one that has a low profile so as to minimize the effect onthe convective currents within the merchandiser. Thus, the cover shouldjust clear the top of the single-texture products being warmed, e.g.,for brownies a cover of about 1 inch in height should be suitable. Thecover acts to trap moisture within the cover and to inhibit or avoid thedrying that would otherwise occur at the edges of the brownies or otherbaked products. The cover can be porous, i.e., have one or more holes orapertures therein, if some moisture loss is desired or can be entirelysealed if minimizing the moisture loss is desired.

[0057] When it is desired to provide controlled drying in a previouslybaked dough product, the product should be kept chilled, or preferablyfrozen, until shortly prior to being placed in the merchandiser of theinvention. “Shortly prior” means less than 2 hours, preferably no morethan about 1 hour, and more preferably the baked dough product is pulledfrom the freezer and promptly placed in the merchandiser, optionallyjust after being thawed and warmed in an oven, e.g., for up to 10minutes. Preferably, the baked dough products in which a dual textureand controlled drying are desired should not be thawed until they becometoo soft, particularly under ambient conditions, as the moisture wouldtend to equilibrate, and consequently, the fresh baked moisture profilewould not be provided during warming in the merchandiser.

[0058] In one embodiment, the apparatus can be constructed with thefollowing dimensions. The size can be from about 12 to 24 inches wide,about 12 to 24 inches deep, and about 20 to 30 inches in height (notincluding the optional housing over the walls). Although other amountsare possible, it is desired to place anywhere from 12 to 48 2-oz. bakedproducts in the apparatus. The heat source is designed to heat theenclosure to a temperature from about 95° F. to 150° F., preferably fromabout 110° F. to 130° F. In varying embodiments, the equipment isdesigned to achieve a desired enclosure temperature of about 110° F. to115° F., about 115° F. to 120° F., about 120° F. to 125° F., and about125° F. to 130° F.

[0059] The temperature in the enclosure is preferably controlled toremain substantially constant or entirely constant. Preferably, thetemperature remains at least substantially constant at every pointthroughout the entire enclosure, which is a result of the optional, butpreferred, air circulation and the size and shape of the enclosure. Tocontrol the temperature to be substantially constant over time, anysuitable device to control the temperature can be employed, such as aconventional bimetallic spring loaded thermostat coupled with anoperator controlled temperature gauge (controller). This systemtypically provides a temperature that remains within about 10° F. of thedesired fixed temperature. Some conventional systems are only able toachieve a temperature within 15° F. of the desired temperature.Preferably, however, the temperature is more constant than thisvariation. Particularly preferred temperature controlling devicesinclude the “electronic controller” types, which include thosecommercially available from Oven Industries and from ChurchillEngineering, each of which will more precisely control the heat towithin 4° F., preferably even within 2° F., of the desired temperature.Proportional controllers regulate the electric power based on a signalthat is proportional to the differential of sensor temperature from theset point and they are typically integrated with the solid staterectifier to provide more constant temperatures when substantiallyconstant temperature is important. In one preferred embodiment, thethermometer used in conjunction with the rectifier and either type ofcontroller is disposed adjacent to a wall having no aperture therein.The thermometer is also preferably disposed sufficiently far from theheat source and the one or more apertures to avoid having the readingsinaccurately altered, i.e., the thermometer is preferably not next to aheating coil or light bulb.

[0060] The invention also includes a merchandizing system 100 depictedin FIG. 3 that includes a modular device 100 wherein the merchandiser110 described above is packaged with a warming compartment 120 with ahigher temperature than the merchandiser 110. It should be understoodthat the merchandiser 110 warms frozen baked products over about 30 to60 minutes before they have both a suitable dual texture and aresuitable for consumption. In this modular system, frozen cookiespreviously baked can be thawed and rapidly warmed in the warmingcompartment 120 in less than about 10 minutes, preferably less thanabout 5 minutes, and more preferably in about 1 to 3 minutes to permitmore rapid sales of baked products. The warming compartment 120 ispreferably sized and configured to receive the same size support surface45, 50 used in the merchandiser 110 as described herein. For example,the warming compartment 120 can be one or more slots or drawers 130 intowhich the trays or sheets 45, 50 can be inserted for rapid thawing.

[0061] The baked products can be disposed on a support surface that iseasily placed in the warming compartment for sufficient time to beginthe warming but insufficient for the desired moisture gradient in thebaked products to be destroyed. Once sufficient warming has occurred,the support surface can be removed from the warming compartment andplaced in the merchandiser to be slowly warmed for display, sale, andconsumption. Preferably, the merchandising system is arranged so thatthe merchandiser is disposed over the warming compartment to keep themerchandiser readily accessible to consumers. This embodimentconveniently avoids the need for a separate oven to rapidly warm frozenbaked products such as cookies in case there is huge demand, avoids theneed to transport the baked products from another area in the kitchenwhere an oven might be located, avoids the need to tie up oven space ortime or to alter the oven settings from other typical uses, can be usedin a retail or convenience store where an oven is not feasible from aneconomic, electricity, space, or other standpoint.

[0062] The warming compartment is typically operated at a temperature ofabout 275° F. to 500° F., preferably from about 300° F. to 475° F., andin one embodiment this is accomplished by convection heating. In apreferred embodiment, the warming compartment can operate from about350° F. to 425° F. The warming compartment can include a controller forautomatic cycling so that the compartment will automatically open andeject the support surface of thawed, baked goods when the heating cycleis complete. This avoids overdrying, as well as aids the clerk operatingthe equipment. Alternatively, an alarm can be set to automatically ringor buzz when the heating cycle is over. Another benefit of themerchandising system is that heat from the warming compartment will riseand assist in maintaining the temperature of the merchandisingcompartment above, which further reduces energy costs of running thesystem.

[0063] Placing frozen baked products in the merchandiser typicallyrequires a short wait, e.g., 15 minutes, 30 minutes, 60 minutes, or thelike, before the baked products are sufficiently thawed and have theirfresh-baked characteristics to be ready for consumption. When productsare first rapidly thawed in the warming compartment, they can be movedinto the merchandiser for display and sale. If warmed properly, thewarming compartment can speed the baked products' preparation so theyare ready for consumption with a proper fresh-baked moisture profileafter a much shorter time in the merchandiser.

[0064] For convenience, both the merchandiser and the warmingcompartment are configured to receive the same size trays. These trayscan be used to initially support the frozen products before warming andthen can support the baked products in the merchandiser. Thus, theproducts can be placed on the trays, warmed in the warming compartmentand the trays can then simply be relocated to the merchandiser.

EXAMPLES

[0065] The invention is further illustrated, but not limited, in thefollowing working examples, where all percentages and parts are byweight.

Example 1

[0066] A Prior Art Thaw and Serve Cookie

[0067] Cookies having a 4 inch diameter were previously baked andfrozen. These cookies were thawed under ambient conditions and themoisture content measured over time at the outer zone, central zone, andan intermediate zone therebetween. Moisture Content (%) Edge ZoneIntermediate Zone Central Zone After 1 hour 5.8% 6.9% 8.5% After 3 hours5.8% 8.1% 8.4% After 6 hours 5.4%   7% 8.1%

[0068] As demonstrated, the cookies according to the prior art has aninsufficient drying, or moisture loss, from the outer zone. Thus,cookies merely thawed and served after having equilibrated with ambientconditions do not have the most desired moisture profile.

Example 2 A Prior Art Apparatus Using a Wire Rack

[0069] Cookies having a 4 inch diameter were previously baked andfrozen. These cookies were placed on an open wire rack in a conventionalapparatus used to warm and display cookies. The wire rack hadapproximately a 78% open area between wires. The moisture content of thecookies was measured over time at the outer zone, central zone, and anintermediate zone therebetween, using the same definitions of thesezones as for Example 1. Moisture Content (%) Edge Zone Intermediate ZoneCentral Zone After 1 hour 4.2% 6.7% 8.6% After 3 hours 4.2% 5.7% 7.6%After 6 hours   2% 4.5%   7%

[0070] As demonstrated, frozen cookies warmed by a prior art apparatushave too much drying, or moisture loss, from the central zone. The outerzone has lost a significant, but acceptable, amount of moisture over 6hours. Thus, cookies warmed in a device that does not sufficientlycontact and protect the previously baked products being warmed did nothave a desired moisture profile.

Example 3 A Cookie Prepared According to a First Embodiment of theInvention

[0071] Cookies having a 4 inch diameter were previously baked andfrozen. These cookies were placed on a solid tray in an apparatusaccording to the invention used to warm and display the cookies. Thesolid tray had 0% open area and the apparatus employed a resistanceheating element (e.g., Calrod) for heating with no direct line of sightto the cookies. Thus, the apparatus employed a fan to provide indirectheating by blowing the air warmed by the lamps over and about thecookies. The moisture content of the cookies was measured over time atthe outer zone, central zone, and an intermediate zone therebetween,using the same definitions of these zones as for Example 1. MoistureContent (%) Edge Zone Intermediate Zone Central Zone After 1 hour   5%6.8% 8.5% After 3 hours 3.5%   6% 8.5% After 6 hours 2.6%   5% 8.3%

[0072] As demonstrated, the method using the apparatus according to theinvention provided a desired moisture profile in the baked products evenup to 6 hours. The outer zone lost sufficient moisture to provide acrispy, drier edge and the central zone retained sufficient moisture toprovide a chewy, moist center.

Example 4 A Cookie Prepared According to a Second Embodiment of theInvention

[0073] Cookies having a 4 inch diameter were previously baked andfrozen. These cookies were placed on a solid tray in another apparatusaccording to the invention used to warm and display the cookies. Thesolid tray had 0% open area and the apparatus employed convectionheating below the tray to warm the cookies. A small air gap was providedbetween the conduction heating coils and the tray to facilitate moreuniform heating of the underside of the tray on which the cookies weredisposed. No fan was used. The moisture content of the cookies wasmeasured over time at the outer zone, central zone, and an intermediatezone therebetween, using the same definitions of these zones as forExample 1. Moisture Content (%) Edge Zone Intermediate Zone Central ZoneAfter 1 hour 4.9% 6.3% 8.8% After 3 hours 3.5% 5.9% 8.9% After 6 hours2.8% 5.6%   8%

[0074] As demonstrated, this second apparatus according to the inventionprovided a desired moisture profile in the baked products even up to 6hours. Again, the outer zone lost sufficient moisture to provide acrispy, drier edge and the central zone retained sufficient moisture toprovide a chewy, moist center.

[0075] The term “about,” as used herein, should generally be understoodto refer to both numbers in a range of numerals. Moreover, all numericalranges herein should be understood to include each whole integer withinthe range.

[0076] In some embodiments where the term “substantially” is used, thatterm is generally defined to mean at least about 90 percent of the valuereferred to, preferably at least about 95 percent of the value referredto, and more preferably at least about 99 percent of the value referredto. Correspondingly, the value will not be more than about 110 percentof the value, preferably less than about 115 percent of the value, andmore preferably less than about 101 percent of the value. Thus, forexample, if the temperature is 95° F. and is “substantially uniform” itwill be not less than about 90 percent or more than about 110 percent ofthat temperature.

[0077] The term “baked,” as used herein, refers to a dough productcooked to some degree to create a moisture gradient therein.

[0078] It is to be understood that the invention is not to be limited tothe exact configuration as illustrated and described herein. Forexample, it should be apparent that a variety of materials would besuitable for use in the composition or method of making the inventionaccording to the Detailed Description. Accordingly, all expedientmodifications readily attainable by one of ordinary skill in the artfrom the disclosure set forth herein, or by routine experimentationtherefrom, are deemed to be within the spirit and scope of the inventionas defined by the appended claims.

What is claimed is:
 1. A modular merchandiser system for displaying andwarming previously baked dough products under controlled dryingconditions, which comprises: a merchandiser comprising: an enclosurehaving one or more wall members that define an interior space visuallyaccessible from outside the enclosure, at least one aperture for accessinto the interior space, at least one support surface for supporting oneor more previously baked dough products that contain a predeterminedaverage moisture level therein, and at least one mounting structureassociated with the enclosure for mounting and positioning each supportsurface at a user accessible location in the interior space of theenclosure; and a heat source for providing heated air in the enclosurewherein the support surface contacts at least a portion of thepreviously baked products so that those portions are shielded fromdirect contact with the heated air such that the drying of moisture inthe baked products is controlled to maintain the organoleptic and/ortexture properties of the products at essentially the same level asthose of freshly baked products for a period of at least about 2 hours;and a warming compartment disposed adjacent to the merchandiser.
 2. Themodular merchandiser system of claim 1, wherein the merchandiser isdisposed over the warming compartment.
 3. The modular merchandisersystem of claim 1, wherein the warming compartment comprises a heatsource that operates at a temperature higher than the merchandiser tothaw previously baked cookies in a reduced amount of time.
 4. Themodular merchandiser system of claim 1, wherein the warming compartmentcomprises a heat source that operates at a temperature of about 300° F.to 475° F. to thaw previously baked frozen cookies in less than about 10minutes.
 5. The modular merchandiser system of claim 4, wherein the heatsource operates at a temperature of about 350° F. to 425° F. to thawfrozen cookies previously baked in less than about 5 minutes.
 6. Themodular merchandiser system of claim 1, wherein the warming compartmentcomprises at least one mounting member for engaging the at least onesupport surface.
 7. The modular merchandiser system of claim 1, whereinthe warming compartment comprises at least one controller for automaticcycling to alert an operator that the thawing cycle is completed.
 8. Themodular merchandiser system of claim 7, wherein the at least onecontroller opens the warming compartment when the heating cycle iscomplete.
 9. The modular merchandiser system of claim 7, wherein the atleast one controller ejects the support surface of thawed, baked goodsafter the compartment opens.
 10. The modular merchandiser system ofclaim 7, wherein the at least one controller initiates an audible orvisible alarm when the heating cycle is completed.